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ALLU Screener Crusher INSTRUCTION MANUAL D SERIES Type Serial number www.allu.net ALLU Finland Oy Jokimäentie
ALLU Screener Crusher
INSTRUCTION MANUAL
D SERIES
Type
Serial number
www.allu.net
ALLU Finland Oy
Jokimäentie 1, 16320 Pennala, Finland
Tel:+358 (0)3 882 140, Fax:+358 (0)3 882 1440, E-mail:info@allu.net

Table of contents

1 General information

4

1.1 The purpose of the instructions

4

1.2 Identification

5

1.3 Manufacturer

5

1.4 CE marking and conformity declaration

5

1.5 The content of the EC-conformity declaration

6

1.6 The scope of the manual

6

1.6.1

The screener crusher models covered by this manual

7

1.7

Copying

7

2 Safety and the environment

8

2.1

Safety notations

8

2.1.1 Explanations for symbols

9

2.1.2 Safety markings on the Screener crusher

10

2.2

Danger zones and exposure to dangers during work

11

2.2.1 Danger zone I (5 m)

11

2.2.2 Danger zone II (20 m)

12

2.3

Exposure to dangers in connection with transport and maintenance

13

2.3.1 The Screener crusher tipping over or falling

13

2.3.2 High-pressure spray

13

2.3.3 Unintentional start-up

14

2.3.4 Environmental damage

14

2.4 User responsibilities and general safety instructions

15

2.5 Intended use and operating environment

16

2.5.1 Intended use

16

2.5.2 Operation range

16

2.5.3

Unanticipated and incorrect use

17

2.5.4

Repairs and changes

17

3 Entry into service and use

18

3.1

Transport, lifting, and storage

18

3.1.1 Transport

18

3.1.2 Lifting and transfer

18

3.1.3 Long-term storage

20

3.2

Attachment to the base machine

20

3.2.1 Mechanical attachment and adapters

20

3.2.2 Diagrams of adapters

23

3.2.3 Attachment to the base machine

24

3.2.4 Connection of the hydraulic system and requirements for the system

24

3.3

New users and procedures before use

30

3.3.1

Inspection upon receipt

30

3.4

Use and operation

31

3.4.1 The principle of operation of the Screener crusher

31

3.4.2 The first start-up and commissioning

31

3.4.3 Correct use

32

3.4.4 Forbidden work methods:

34

4 Maintenance

36

4.1

Maintenance work in connection with use

37

4.1.1 Daily inspection (8 hrs)

38

4.1.2 Weekly inspection (40 hrs)

38

4.2 Extensive maintenance

40

4.3 Replacement of wear parts

42

4.3.1

Replacement of blades (DN, DS, and DH models with XHD drums)

42

4.3.2

Replacement of counter blades (DN, DS, and DH models with XHD and X

drums) ……………………………………………………………………………… 44

4.3.3 Replacement of fine screening blades (DNS, DSB, and DHB models)

46

4.3.4 Replacement of wear parts in TS models and changing of the end-product

size……………………………………………………………………………………49

 

4.3.5 Replacement of TS blades

52

4.3.6 Replacement of the bearing-protection fender

60

4.3.7 Replacement of drums

62

4.3.8 Removal and installation of bearings and chain wheels

68

4.3.9 Maintenance of the bearing unit

71

4.4 Troubleshooting

75

4.5 Disposal

78

5

Technical description

79

5.1 Mounting

dimensions

79

5.2 Technical

specifications

81

5.3 Hydraulic

schematics

84

5.3.1 Connecting the Screener crusher with the base machine’s hydraulic system

84

5.3.2 Single-motor buckets

85

5.3.3 Two-motor buckets

86

5.4

Noise level

88

1

GENERAL INFORMATION

Important information is found in this manual, labels affixed to the product, transport

guidelines, and other country- or project-site-specific guidelines for the safe use of the

product. The manuals constitute an integral and important part of the product and must

always be made available to the user. This manual must always be stored in the cabin of the

base machine in a location where it is readily accessible when necessary. Ensure that the

manual remains clean and intact. When it is necessary, ask for assistance in interpreting the

instructions.

WARNING

WARNING

COMPLIANCE WITH INSTRUCTIONS Read the manual before use or maintenance work, and always comply with the instructions provided. Incorrect handling of the machine creates a risk of death or serious injury.

of the machine creates a risk of death or serious injury. 1.1 The purpose of the
of the machine creates a risk of death or serious injury. 1.1 The purpose of the

1.1 The purpose of the instructions

The instructions are intended to promote safety and the appropriate, correct, and cost-

efficient use of the machine. This manual will help the user to identify, avoid, and prevent

dangerous situations and their consequences.

Operations must comply with these instructions; obey all locally applicable laws, decrees,

and regulations; and employ all locally dictated protective measures (such as practices for

safe work methods).

Read this manual carefully, and follow the instructions meticulously. If something seems

unclear, ask your employer or your nearest ALLU representative for clarification. Each part

of this manual contains information that is important for your safety.

These instructions are also used in user training. Compliance with these instructions helps

to keep maintenance costs and downtime to a minimum and the machine’s reliability and

durability optimal.

1.2

Identification

The Screener crusher’s model and serial number can be found on the machine plate. Check that the model matches the model list in this manual. It is important to indicate the serial number in any discussion about the machine – for example, when ordering spare parts.

the machine – for example, when ordering spare parts. 1.3 Manufacturer This Screener crusher was manufactured
the machine – for example, when ordering spare parts. 1.3 Manufacturer This Screener crusher was manufactured

1.3 Manufacturer

This Screener crusher was manufactured by:

ALLU Finland Oy Jokimäentie 1 16320 Pennala FINLAND Telephone:+358 3 882 140 +358 3 882 1440 Web: www.allu.net E-mail: info@allu.net

1.4 CE marking and conformity declaration

The CE marking can be found on the machine plate. As it leaves the factory, this Screener crusher meets all the health and safety requirements set forth in the Machinery Directive. Store the EC-conformity declaration appropriately, and ensure that it is also passed on to any new owner of the machine.

1.5

The content of the EC-conformity declaration

EC-conformity declaration (2006/42/EC, Appendix II A, Directive 2000/14/EC) The manufacturer: ALLU Finland Oy

Of the address: Jokimäentie 1, 16320 Pennala, FINLAND

Declares that Screener crusher model AAA, serial number ZZZ conforms with the terms of the Machinery Directive (2006/42/EC) and conforms with the terms of the Noise Emission Directive (2000/14/EC).

This conformity declaration is valid if the machine has not undergone any changes not approved by the manufacturer in writing.

N.N., authorised to compile the technical specifications for this machine

N.N.,authorised to prepare this conformity declaration

Date: dd.mm.yy

Place: Jokimäentie 1, 16320 Pennala, FINLAND

1.6 The scope of the manual

This manual contains instructions for safety and on the use, transport, lubrication, and maintenance of this machine in the state it was in when released from the factory.

This manual and the safety instructions, in particular, along with the EC-conformity

declaration, are valid only if changes not approved by the manufacturer have not been made

to the machine.

A different machine model may have been used for some of the manual’s illustrations, or

some covers or similar parts may have been removed to allow for clearer depiction of the situation.

Because the product undergoes continuous improvement and development work, some changes might have been made to it that are not reflected in this manual.

If you have any questions on the product or this manual, please contact your local ALLU representative.

1.6.1 The screener crusher models covered by this manual

DN 2-09

DNS 2-09

DS 3-12

DSB 2-12

DH 3-12

DHB 2-12

DN 2-12

DNS 2-12

DS 3-17

DSB 2-17

DH 3-17

DHB 2-17

DN 2-17

DNS 2-17

DS 3-23

DSB 2-23

DH 3-23

DHB 2-23

DN 3-09

DNS 3-09

DS 4-12

DSB 3-12

DH 4-12

DHB 3-12

DN 3-12

DNS 3-12

DS 4-17

DSB 3-17

DH 4-17

DHB 3-17

DN 3-17 DN 3-12 TS DN 3-17 TS

DNS 3-17

DS 4-23 DSH 3-23 TS DSH 4-23 TS

DSB 3-23

DH 4-23 DH 4-27 DH 3-12 TS DH 3-17 TS DH 4-17 TS

DHB 3-23

1.7 Copying

The copyrights for this manual belong to ALLU Finland Oy, Jokimäentie 1, 16320 Pennala, FINLAND.

It is forbidden to copy or reproduce the manual or parts of it or to otherwise redistribute the manual to third parties without the manufacturer’s written permission.

All rights are reserved.

2

SAFETY AND THE ENVIRONMENT

2.1 Safety notations

The following safety notations are used in this manual:

DANGER The danger sign refers to an immi nent dangerous situation that causes a risk
DANGER The danger sign refers to an immi nent dangerous situation that causes a risk
DANGER The danger sign refers to an immi nent dangerous situation that causes a risk

DANGER

The danger sign refers to an immi nent dangerous situation that causes a risk of

The danger sign refers to an imminent dangerous situation that causes a risk of death or serious injury unless steps are taken to avert it.

WARNING

WARNING

The warning sign refers to a potentially dangerous situation that causes a risk of death or serious injury unless steps are taken to avert it.

or serious injury unless steps are taken to avert it. CAUTION The caution sign refers to

CAUTIONor serious injury unless steps are taken to avert it. The caution sign refers to a

The caution sign refers to a potentially dangerous situation that causes a risk of slight or moderate injury or damage unless steps are taken to avert it.

te injury or damage unless steps are taken to avert it. NOTE A note contains instructions
NOTE A note contains instructions or describes pertin ent regulations.
NOTE A note contains instructions or describes pertin ent regulations.

NOTE

A note contains instructions or describes pertinent regulations.

2.1.1

Explanations for symbols

Warning signs:

General Danger Danger Danger of Danger of Danger Danger danger from related to crushing
General Danger Danger Danger of Danger of Danger Danger danger from related to crushing
General Danger Danger Danger of Danger of Danger Danger danger from related to crushing
General Danger Danger Danger of Danger of Danger Danger danger from related to crushing
General Danger Danger Danger of Danger of Danger Danger danger from related to crushing
General Danger Danger Danger of Danger of Danger Danger danger from related to crushing
General Danger Danger Danger of Danger of Danger Danger danger from related to crushing

General

Danger

Danger

Danger of

Danger of

Danger

Danger

danger

from

related to

crushing

ignition

related to

related to

flying

working

high-

crushing

objects

load

pressure

of the

oil spray

hands or

other body

parts

DO NOT signs:

Do not remain in the danger zone Do not put a hand or fingers between
Do not remain in the danger zone Do not put a hand or fingers between

Do not remain in the danger zone

Do not put a hand or fingers between moving parts

DO signs:

Read and observe the instructions for use Maintain a safe distance Use safety Use a
Read and observe the instructions for use Maintain a safe distance Use safety Use a
Read and observe the instructions for use Maintain a safe distance Use safety Use a
Read and observe the instructions for use Maintain a safe distance Use safety Use a

Read and observe the instructions for use

Maintain a safe distance

Use safety

Use a respirator

goggles

Wear a safety helmet Use hearing Wear protective protection clothing
Wear a safety helmet Use hearing Wear protective protection clothing
Wear a safety helmet Use hearing Wear protective protection clothing

Wear a safety helmet

Use hearing

Wear protective

protection

clothing

2.1.2

Safety markings on the Screener crusher

The following warning markings must be displayed on the ALLU screener crusher. Any damaged or loose warning labels must be replaced.

Any damaged or loose warning labels must be replaced.   DANGE R   RISK OF BEING
 
  DANGE R  

DANGER

 
RISK OF BEING CRUSHED OR THROWN Anyone under five metres from the machine is at
RISK OF BEING CRUSHED OR THROWN Anyone under five metres from the machine is at
RISK OF BEING CRUSHED OR THROWN Anyone under five metres from the machine is at

RISK OF BEING CRUSHED OR THROWN Anyone under five metres from the machine is at risk of being crushed or thrown by a moving or falling machine or by material falling from the Screener crusher!

is at risk of being crushed or thrown by a moving or falling machine or by
is at risk of being crushed or thrown by a moving or falling machine or by
 
  W ARNING  

WARNING

 
COMPLIANCE WITH INSTRUCTIONS Read the manual before use or maintenance work, and always comply with

COMPLIANCE WITH INSTRUCTIONS Read the manual before use or maintenance work, and always comply with the regulations and instructions indicated.

Read the manual before use or maintenance work, and always comply with the regulations and instructions
W ARNING  
W ARNING

WARNING

 
W ARNING  

FLYING OBJECTS Anyone less than 20 metres from the Screener crusher is at risk from flying objects, noise, and dust.

crusher is at risk from flying objects, noise, and dust. W ARNING     RISK OF
crusher is at risk from flying objects, noise, and dust. W ARNING     RISK OF
W ARNING    
W ARNING

WARNING

   

RISK OF HANDS GETTING CAUGHT BETWEEN MOVING PARTS Do not put hands or fingers between moving parts!

PARTS Do not put hands or fingers between moving parts!   W ARNING HIGH-PRESSURE SPRAY Turn
 
  W ARNING

WARNING

  W ARNING
HIGH-PRESSURE SPRAY Turn off the base machine and depressurise the hydraulic system before connecting or

HIGH-PRESSURE SPRAY Turn off the base machine and depressurise the hydraulic system before connecting or servicing the system.

system before connecting or servicing the system.   W ARNING USE PERSONAL PROTECTIVE EQUIPMENT Exposure
 
W ARNING

WARNING

  W ARNING
  W ARNING
USE PERSONAL PROTECTIVE EQUIPMENT Exposure to noise, dust, or flying objects may cause a risk

USE PERSONAL PROTECTIVE EQUIPMENT Exposure to noise, dust, or flying objects may cause a risk of death or serious injury.

PERSONAL PROTECTIVE EQUIPMENT Exposure to noise, dust, or flying objects may cause a risk of death

2.2

Danger zones and exposure to dangers during work

2.2.1 Danger zone I (5 m)

DANGER  
DANGER  

DANGER

 

Stop working immediately if you observe another person in danger zone I.

Stop working immediately if you observe another person in danger zone I.
Stop working immediately if you observe another person in danger zone I.
Material falling from the Screener crusher or a work machine falling creates a risk of
Material falling from the Screener crusher or a work machine falling creates a risk of

Material falling from the Screener crusher or a work machine falling creates a risk of death or serious injury within this zone. Under no circumstances go under the Screener crusher!

WARNING Exposure to high-pressure oil spray within danger zone I causes a risk of deat
WARNING Exposure to high-pressure oil spray within danger zone I causes a risk of deat
WARNING Exposure to high-pressure oil spray within danger zone I causes a risk of deat

WARNING

Exposure to high-pressure oil spray within danger zone I causes a risk of deat h

Exposure to high-pressure oil spray within danger zone I causes a risk of death or serious injury.

WARNING Exposure to high-pressure oil spray within danger zone I causes a risk of deat h
WARNING Exposure to high-pressure oil spray within danger zone I causes a risk of deat h
5 m
5 m

Danger zone I covers an area five metres in every

direction from the Screener crusher and the base

machine. No-one is allowed in danger zone I while the

Screener crusher is in operation. Anyone within five

metres of the machine is at risk from dangers related to

material falling from the machine, high-pressure oil

spray, and machines moving or falling over. The user

must observe the surroundings continuously and stop

working immediately if another person enters the area

within five metres from the Screener crusher or base

machine.

A protective structure must be installed for open-top base machines to protect the user

from falling and flying objects.

2.2.2

Danger zone II (20 m)

WARNING
WARNING

WARNING

WARNING

Stop working immediately if you observe another person in danger zone II

Exposure to material thrown by the Screener crusher in danger zone II causes a risk

Exposure to material thrown by the Screener crusher in danger zone II causes a risk of death or serious injury.

Exposure to material thrown by the Screener crusher in danger zone II causes a risk of
20m
20m

Danger zone II covers an area 20 metres in

every direction from the Screener crusher.

No-one is allowed in danger zone while the

Screener crusher is in operation. Anyone

within 20 metres of the Screener crusher is

at risk from dangers related to material

thrown by the machine, noise, and dust.

The user must observe the surroundings

continuously and stop working

immediately if another person enters the

area within 20 metres of the Screener

crusher.

If, under exceptional circumstances, another person has to enter the danger zones, the

user must be made aware of this, so that he or she can take extra care when operating

the Screener crusher.

2.3

Exposure to dangers in connection with transport and maintenance

2.3.1 The Screener crusher tipping over or falling

  DANGER  
  DANGER  
 
  DANGER  

DANGER

 

Comply with the instructions for lifting and transport, and use suitable and approved equipment when lifting the Screener crusher. No-one is allowed closer than five metres from a Screener crusher that is being lifted or transferred.

A

Screener crusher falling or toppling over causes a risk of

a Screener crushe r that is being lifted or transferred. A Screener crusher falling or toppling
a Screener crushe r that is being lifted or transferred. A Screener crusher falling or toppling
death or serious injury!  

death or serious injury!

 

2.3.2 High-pressure spray

   
    WARNING

WARNING

    WARNING
    WARNING
Before any maintenance work performed in connection with use (see Section 4) and before connecting

Before any maintenance work performed in connection with use (see Section 4) and before connecting or disconnecting the hydraulic system (see Section 3), turn off the base machine and depressurise the hydraulic system by moving the control lever of the auxiliary hydraulic system with only the starter motor turned on.

Exposure to high-pressure oil spray causes a risk of death

with only the starter motor turned on. Exposure to high-pressure oil sp ray causes a risk

or

serious injury.

Seek medical assistance immediately if any hydraulic oil enters your eyes or high-pressure

spray penetrates your skin.

2.3.3

Unintentional start-up

WARNING  
WARNING  
WARNING  

WARNING

 

Detach the Screener crusher from the base machine and disconnect the hydraulic system before changing any wear parts or performing extensive maintenance work (see Section 4), to prevent unintentional start-up. Under no circumstances place your hands between rotating parts while the Screen crusher is attached to the base machine.

Under no circumstances place your hands between rotating parts while the Screen crusher is attached to
Falling under a moving Screener crusher or getting caught between rotating parts causes a risk

Falling under a moving Screener crusher or getting caught between rotating parts causes a risk of death or serious injury!

2.3.4 Environmental damage

 
  CAUTION  

CAUTION

 
Stop working immediately if you observe leakage of oil or another lubricant. Turn off the

Stop working immediately if you observe leakage of oil or another lubricant. Turn off the base machine and depressurise the hydraulic system by moving the control lever of the auxiliary hydraulic system with only the starter motor turned on.

hydraulic sy stem by moving the control lever of the auxiliary hydrauli c system with only

Minimise the environmental damage by using solid material such as sand or peat to absorb

the leaking lubricant. Dispose of the contaminated sand or other material in an appropriate

manner.

2.4

User responsibilities and general safety instructions

 
  WARNING  

WARNING

 
The Screener crusher is to be installed, used, and serviced by only a person who

The Screener crusher is to be installed, used, and serviced by only a person who has read and understood this manual and has the knowledge, skills, and experience required for safe and appropriate work methods. Always adhere to all general and specific safety regulations and take the measures applicable.

work methods. Always adhere to all general and specific safety regulations and take the measures applicable.

Incorrect installation, inappropriate use, or incorrectly performed maintenance of the machine creates a risk of death or serious injury!

WARNING

WARNING

Use the protective personal equipment required by the working conditions and project-site specific regulations.

Being exposed to noise, dust, or flying objects causes a risk of death or serious injury.

flying objects causes a risk of deat h or serious injury. The user must find out
flying objects causes a risk of deat h or serious injury. The user must find out
flying objects causes a risk of deat h or serious injury. The user must find out
flying objects causes a risk of deat h or serious injury. The user must find out
flying objects causes a risk of deat h or serious injury. The user must find out

The user must find out in advance any country- or project-site-specific safety regulations on

the use of protective personal equipment, safety of the machines, and work methods when

one is using a Screener crusher and must comply with said regulations. This owner’s manual

must be kept in the cabin of the base machine, so that the instructions are readily available.

The following are general regulations, prohibitions, and instructions to which the user must

adhere:

The Screener crusher must never be used by someone under the influence of alcohol

or illegal substances.

The Screener crusher must never be used for lifting or transporting people.

The Screener crusher must never be serviced, inspected, repaired, or checked while

the engine of the base machine is running.

The Screener crusher is to be operated only from the cabin of the base machine.

The user must learn about the features of the base machine, including

depressurisation of the hydraulic system.

The user must always use the personal protective equipment required by the

operating environment, conditions, and regulations.

The user must always stop working when another person enters the danger zones.

The user must inform other persons on the project site when, for instance, the

Screener crusher is being moved to a different location or is being transferred, to

prevent people from unintentionally entering the danger zones.

2.5 Intended use and operating environment

2.5.1 Intended use

The Screener crusher is a hydraulic attachment to be used with hydraulic excavators, wheel

loaders, and similar base machines for the screening, crushing, pulverising, mixing, and

feeding of a variety of materials.

The Screener crusher is not designed for digging of soil, crushing of hard stones, or

transferring of large and heavy objects.

2.5.2 Operation range

DANGER Do not use the Screener crusher in an environment with an ignition or combustion
DANGER Do not use the Screener crusher in an environment with an ignition or combustion
DANGER Do not use the Screener crusher in an environment with an ignition or combustion
DANGER Do not use the Screener crusher in an environment with an ignition or combustion

DANGER

Do not use the Screener crusher in an environment with an ignition or combustion risk!

Do not use the Screener crusher in an environment with an ignition or combustion risk!

A fire or explosion resulting from a sp ark causes a risk of death or

A fire or explosion resulting from a spark causes a risk of death or serious injury!

The Screener crusher is to be operated only outdoors and in indoor spaces suitable

for work with such machines.

The Screener crusher’s intended operating temperature range is -25 °C to 60 °C.

Use of the Screener crusher underwater is forbidden without project-site specific risk assessment and safety measures, because of the risk of an oil leak.

In work with hazardous or toxic materials, the appropriate safety measures and personal protective equipment must be in use.

2.5.3

Unanticipated and incorrect use

The Screener crusher is intended for the processing of various materials, as described in this manual. ‘Unanticipated and incorrect use’ refers to all use that is not in line with this manual. Unanticipated or incorrect use may create a risk of casualties or damage to the Screener crusher, the base machine, or the environment.

2.5.4 Repairs and changes

ALLU Screener crushers are to be repaired and equipped with only genuine ALLU spare parts and accessories. It is forbidden to make any changes to the Screener crusher without written permission from the manufacturer.

3

ENTRY INTO SERVICE AND USE

3.1 Transport, lifting, and storage

3.1.1 Transport

USE 3.1 Transport, lifting, and storage 3.1.1 Transport When transporting a Screener crusher, secure it separately

When transporting a Screener crusher, secure it separately to the transport equipment, with its bottom facing downward.

3.1.2 Lifting and transfer

its bottom facing downward. 3.1.2 Lifting and transfer For lifting and transfer , connect hoist belts

For lifting and transfer, connect hoist belts or chains to the hoist rings fixed to the threaded holes further back in the adapter. If an adapter has been installed for the Screener crusher, secure the hoist belts or chains around parts from which they cannot come loose.

The weight of the Screener crusher (without accessories and an adapter) is stated on the machine plate and in the table of technical data in this manual.

When using a forklift, always lift the Screener crusher from the side of the drums.
When using a forklift, always lift the Screener crusher from the side of the drums.
When using a forklift, always lift the Screener crusher from the side of the drums.

When using a forklift, always lift the Screener crusher from the side of the drums.

Never lift the Screener crusher from the side of the lip shroud. Hoisting the Screener crusher from the lip shroud side may cause it to topple over, because its centre of gravity is high and toward the back.

Never disconnect the Screener crusher from the base machine or a hoisting device on a sloping or soft surface, to prevent it from falling over. Note the risk of falling when loosening the straps used to secure the Screener crusher for transport.

3.1.3

Long-term storage

Store the Screener crusher protected from the weather.

Before long-term storage:

Wash and lubricate the Screener crusher.

Remove any rust and paint the affected surfaces.

Protect the bare metal surfaces with an anti-corrosive agent.

Plug any open hydraulic connections.

3.2 Attachment to the base machine

3.2.1 Mechanical attachment and adapters

The Screener crusher is mounted on the base machine with an adapter.

The Screener crusher is mounted on the base machine with an adapter that has lugs specific

to the base machine’s accessory mount welded to it.

The adapter’s mounting bolts:

Screener crusher model

Bolt size

 

Tightening torque

DN, DNS, DS, DSB

M20 (10.9)

540

Nm (oiled threading)

DH, DHB

M24 (10.9)

960

Nm (oiled threading)

 
  WARNING  

WARNING

 
Always mount the adapter carefully, complying with the instructions in order to ensure the required

Always mount the adapter carefully, complying with the instructions in order to ensure the required strength. Attach all the bolts, and always use stretch sleeves, suitable bolts, and the correct tightening torque.

strength. Attach all the bolts, and always use st retch sleeves, suitable bolts, and the correct

A Screener crusher coming loose and falling causes a risk of death or serious injury!

3.2.1.1

Installation of the excavator adapter

The Screener crusher may be mounted in either the backhoe or the face shovel position. The mounting arrangement selected determines which way the adapter has to be mounted on the Screener crusher.

2 1
2
1
2 1
2
1

When the Screener crusher is mounted in the backhoe position (‘the standard position’), the basic plate’s shield [2] is placed on the front of the Screener crusher. Tighten the bolts in the order presented in the picture, first to half the tightening torque specified in the table, then to the full tightening torque on the second round. Use stretch sleeves [1] under each mounting pin.

When the Screener crusher is mounted in the face shovel position, the basic plate’s shield [2] is placed at the back of the Screener crusher. Tighten the bolts in the order presented in the picture, first to half the tightening torque specified in the table, then to the full tightening torque on the second round. Use stretch sleeves [1] under each mounting pin.

3.2.1.2

Installation of the wheel loader adapter

3.2.1.2 Installation of the wheel loader adapter Two-part wheel loader basic plate: Tighten the bolts in
3.2.1.2 Installation of the wheel loader adapter Two-part wheel loader basic plate: Tighten the bolts in

Two-part wheel loader basic plate: Tighten the bolts in the order shown in the picture, first to half the tightening torque specified in the table, then to the full tightening torque on the second round.

One-part wheel loader basic plate: Tighten the bolts in the order shown in the picture, first to half the tightening torque specified in the table, then to the full tightening torque on the second round.

3.2.2

Diagrams of adapters

3.2.2 Diagrams of adapters Excavator adapter, direct pin mounting. Wheel loader adapter, quick connection (similar to
3.2.2 Diagrams of adapters Excavator adapter, direct pin mounting. Wheel loader adapter, quick connection (similar to
3.2.2 Diagrams of adapters Excavator adapter, direct pin mounting. Wheel loader adapter, quick connection (similar to

Excavator adapter, direct pin mounting.

Wheel loader adapter, quick connection (similar to Volvo).

Wheel loader adapter, Z link connection.

3.2.3

Attachment to the base machine

3.2.3 Attachment to the base machine Always attach and detach a Screener crusher on a solid,
3.2.3 Attachment to the base machine Always attach and detach a Screener crusher on a solid,

Always attach and detach a Screener crusher on a solid, even surface in such a way that the Screener crusher’s bottom plate is toward the ground.

Never place the Screener crusher upside down on the ground.

3.2.4

Connection of the hydraulic system and requirements for the system

3.2.4.1

Hydraulic oil requirements for the base machine

A high-quality, mineral-based hydraulic oil with additives that has been approved by the base machine’s manufacturer must be used with the Screener crusher. The viscosity class of the hydraulic oil must be selected such that, at normal operating temperature, the oil’s viscosity is as close to the recommended value as possible. If the viscosity differs from the recommended values, the service life of the motor becomes shorter.

ISO VG viscosity classification in accordance with operating temperature:

Maximum operating temperature for

ISO VG classification for hydraulic

40–50 °C

46

50–60 °C

68

60–80 °C

100

Values for hydraulic oil:

Recommended operating temperature for

30–60 °C

Recommended oil viscosity at operating

35 cSt

Allowed viscosity

20–75 cSt

If the hydraulic oil continuously remains at a high temperature, its service life becomes shorter. Change the hydraulic oil at the intervals specified in the base machine’s service programme.

3.2.4.2 The filtering and cooling of hydraulic oil

The maximum rate of hydraulic oil contamination allowed in accordance with ISO 4406 is 20/16. The highest recommended nominal filtering rate is 25 μm.

In demanding applications, the Screener crusher may produce a large quantity of heat, which is mainly transferred to the base machine’s hydraulic system. Therefore, it is recommended that the base machine have a cooling system for hydraulic oil.

3.2.4.3 Hydraulic settings for the base machine

The Screener crusher requires two-way hydraulics to allow the drums to rotate in both directions. Set the hydraulic flow in accordance with the range specified on the machine plate (and in the technical data).

It is not necessary to limit the maximum pressure in the device circuit of the base machine. All D-series Screener crushers come with a power control valve to protect the Screener crusher against hydraulic overload. The power control valve begins to control the engine’s pressure difference when this value exceeds 280 bar and the hydraulic flow when it exceeds the model-specific maximum value.

In excavators, the recommended range for the maximum pressure setting for the device

circuit is 300–340 bar. For wheel loaders, it is recommended that the highest pressure setting

available be selected as the maximum pressure setting for the device circuit.

The base machine’s valves and pipes create back pressure in the operating hose acting as the

return line, which typically ranges from around 10 to 30 bar, depending on the base machine.

High back pressure causes, among other things, a power reduction and heating of the

hydraulic oil.

NOTE

Set the base machine’s hydraulic flow to be as low as possible without affecting the capacity. An unnecessarily high rotation speed increases fuel consumption, causes heating of the hydraulic oil, and speeds up the wearing of the engine and wear parts.

and speeds up the wearing of the engine and wear parts. 3.2.4.4 Drain line In addition

3.2.4.4 Drain line

In addition to two-way hydraulics, a low-pressure drain line is needed in the base machine

to carry the oil accumulating in the hydraulic motor case back to the base machine’s

hydraulic tank.

1 2 3
1
2
3

Oil accumulated in the Screener crusher is

carried to the base machine’s hydraulic

tank [3] via a drain line [1]. The drained oil

can either be filtered via a separate filter

[2] or directed to the return filter of the

base machine (see the diagram in section

5.3.3).

NOTE

Drained oil must not be directed through valves, taps, or similar; it must pass directly via the filter to the hydraulic tank, to prevent an increase in back pressure or the unintentional closing of the drain line. The back pressure in the drain line must not exceed 30 bar. Excessive pressure in the drain line damages the hydraulic motor.

pressure in the drain line damages the hydraulic motor. A safety valve is available as an

A safety valve is available as an accessory for the Screener crusher to protect the hydraulic

motor from high back pressure in the drain line.

If a drain line cannot be used, an elimination system for the drain line can be obtained for

the Screener crusher as an accessory. A separate drain line should, however, be used

whenever possible.

2
2

3.2.4.5 Hoses and connections

Connections:

If an elimination system for the drain line,

available as an accessory, has been

installed for the Screener crusher, the

restricting valve for the pressure in the

motor case is connected to the port [2]. If

the back pressure in the base machine’s

return line exceeds 30 bar, the pressure

restricting valve opens and oil flows out

via the sieve that protects the port [2].

Screener crusher

Operating ports

Drain port

Pressure port

model

All models

G1" female

G3/8" female

G1/4" female thread

thread

thread

Recommended minimum hose sizes:

Screener crusher model

Operating hoses

Drain line

DN models

3/4" (min. nominal pressure 350 bar)

3/8"

DNS and DN TS models

1" (min. nominal pressure 350 bar)

3/8"

DS, DH, DSB, and DHB

1" (min. nominal pressure 350 bar)

3/8"

models

 
  WARNING

WARNING

  WARNING
  WARNING
Before connecting or disconnecting the hydraulic system, turn off the base machine and depressurise the

Before connecting or disconnecting the hydraulic system, turn off the base machine and depressurise the hydraulic system by moving the control lever of the auxiliary hydraulic system with only the starter motor turned on.

Exposure to high-pressure oil spray from a pressurised connection causes a risk of death or serious injury.

CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and
CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and
CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and

CAUTION

Minimise the risk of hydraulic oi l entering the environment by having basins and material

Minimise the risk of hydraulic oil entering the environment by having basins and material for absorbing any leaks available while making connections!

2 1
2
1

1. Connect the operating hoses and drain

line by using suitable connectors.

Operating connections [1] and drain

connection [2]. Never climb on the

Screener crusher to make

connections.

2. Route the hoses to the base machine in

such a way that they do not press

against sharp edges. When necessary,

use 45° or 90° hose fittings.

3. After completing the connections, run

the Screener crusher through its entire

range of positions to ensure that the

hoses do not stretch or become

crushed in any of the positions.

NOTE

NOTE

When using quick-release connectors, take extra care, particularly when connecting the drain line, to prevent a rise in pressure or rupturing of the drain line.

3.2.4.6 Disconnection of the hydraulic system

 
  WARNING

WARNING

  WARNING
  WARNING
Before connecting or disconnecting the hydraulic system, turn off the base machine and depressurise the

Before connecting or disconnecting the hydraulic system, turn off the base machine and depressurise the hydraulic system by moving the control lever of the auxiliary hydraulic system with only the starter motor turned on.

Exposure to high-pressure oil spray from a pressurised connection causes a risk of death or serious injury.

CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and
CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and
CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and

CAUTION

Minimise the risk of hydraulic oi l entering the environment by having basins and material

Minimise the risk of hydraulic oil entering the environment by having basins and material for absorbing any leaks available while making connections!

2 1
2
1

Detach the hoses, and plug any open

connections [1] [2] in the Screener

crusher. If the hoses are left attached to

the Screener crusher, plug and cover the

hose ends. Never climb on the Screener

crusher to undo connections.

NOTE

Prevent any dirt form entering the hydraulic oil, by keeping the connections clean and covered and by preventing open connections from coming into contact with the ground. Dirt is harmful to all components of the hydraulic system and shortens their service life.

of the hydraulic system and shor tens their service life. 3.3 New users and proce dures

3.3 New users and procedures before use

3.3.1 Inspection upon receipt

When you receive a new Screener crusher, make sure it is accompanied by the following

documents:

Instruction manual

Spare-parts list

Warranty registration form and warranty terms

Fill in the warranty registration form and send it to your ALLU representative.

3.4

Use and operation

3.4.1 The principle of operation of the Screener crusher

The Screener crusher is a hydraulic attachment to be used with hydraulic excavators, wheel

loaders, and similar base machines for the screening, crushing, pulverising, mixing, and

feeding of a variety of materials. The Screener crusher can process a wide range of materials,

including topsoil, excavated soil, sand, gravel, blacktop and dirt, clay, peat, coal, bark,

compost, organic waste, construction waste, milled asphalt, and glass.

The processing takes place in the Screener crusher with the assistance of drums rotating in

the same direction, powered by one or more hydraulic motors. The rotation direction and

speed of the drums are adjusted with controls on the base machine. In the processing of

materials, the fine matter passes through the drums on account of their movement and falls

into a pile under the Screener crusher. Large and uncrushed pieces remain in the bucket,

from which they can be tipped onto another pile. The processing characteristics, such as the

strength of the crushing and the fragment size produced, can be influenced by the choice of

drums and blades.

3.4.2 The first start-up and commissioning

 
  WARNING

WARNING

  WARNING
  WARNING
Before inspecting connections, turn off the base machine and depressurise the hydraulic system by moving

Before inspecting connections, turn off the base machine and depressurise the hydraulic system by moving the control lever of the auxiliary hydraulic system with only the starter motor turned on.

Exposure to high-pressure oil spray from a pressurised connection causes a risk of death or serious injury.

Perform the following steps before use:

Tip the Screener crusher into various positions, to ensure that it cannot hit the boom

of the base machine and that the hydraulic hoses are not going to get stretched or

crimped.

Tip the Screener crusher such that the drums can be seen from the cabin of the base machine. Rotate the drums for approximately two minutes at low speed in both directions, to remove any air from the hydraulic system. Keep an eye out for any leaks.

Check the hydraulic hoses and connections for leaks and damage.

Visually check that the adapter mounting bolts are not loose.

3.4.3

Correct use

r mounting bolts are not loose. 3.4.3 Correct use 0° 45° The rotation direction of the
0° 45°
45°

The rotation direction of the drums (bottom upward) is designed to roll the material inside the Screener crusher, which helps to separate finer material. If the material does not pass through properly or the Screener crusher becomes blocked, tilt the bucket or use the other rotation direction for a short while.

The intended operating angle ranges from 0° to 45° from horizontal level in relation to the back wall.

Check that the position range of the base machine’s booms allows the Screener crusher to be tilted within the operating range presented in the picture (in some cases, tilting to the 0° position is not possible).

The best operation angle depends on the material being processed. Various angles should be tested when work is commenced.

20° 90°
20°
90°

Other operation tips:

The intended emptying angle is 20° to 90° from horizontal level in relation to the bottom plate.

Check that the position range of the base machine’s booms allows the Screener crusher to be tilted within the emptying range presented in the picture.

Change any wear parts in good time. Worn blades reduce capacity and affect the fragment size.

Clean the Screener crusher regularly when working with materials that are likely to stick. Such materials adhere to the interior surfaces of the Screener crusher, drums, and counter blades, reducing its capacity and creating additional strain.

The drums should be stopped before the bucket is completely empty, to keep stones from being thrown and to improve the overall capacity (material usually passes through more slowly when the Screener crusher is nearly empty).

3.4.4

Forbidden work methods:

3.4.4 Forbidden work methods: Never move material by pushing it with the Screener crusher’s drums, as
3.4.4 Forbidden work methods: Never move material by pushing it with the Screener crusher’s drums, as
3.4.4 Forbidden work methods: Never move material by pushing it with the Screener crusher’s drums, as

Never move material by pushing it with the Screener crusher’s drums, as this could damage the sealing of the bearings.

Never use the sides of the Screener crusher to move material: that could damage the Screener crusher.

Never use the Screener crusher as a support when moving the base machine, as this may damage the Screener crusher.

Do not continuously change the Screener crusher rotation direction: doing so could cause the power
Do not continuously change the Screener crusher rotation direction: doing so could cause the power
Do not continuously change the Screener crusher rotation direction: doing so could cause the power

Do not continuously change the Screener crusher rotation direction: doing so could cause the power transmission to wear out more rapidly. Bring the drums to a standstill cautiously before changing the rotation direction.

Do not overfill the Screener crusher, as that may cause a loss of stability in the base machine and block the Screener crusher.

Be sure to keep large stones from entering the bucket, to avoid excessive wear.

4

MAINTENANCE

The Screener crusher’s maintenance programme consists of daily and weekly inspections

and weekly and annual servicing. As part of the inspection procedures, the condition of the

structures, wear parts, and power transmission is checked and any stones and similar

fragments caught in the Screener crusher are removed. As part of servicing, the power

transmission’s lubrication is changed or lubricants topped up, and its components are

checked (and replaced as necessary).

The schedule for the replacement of any wear parts is not specified in the Screener crusher’s

maintenance programme, because the wear to these components depends on operating

conditions and the material processed. The Screener crusher components that are most likely

to experience wear are the blades and counter blades. The wearing of these components is

checked in connection with each inspection, and the parts are replaced before they get worn

to such an extent that continuing to work will create wear to holding structures or the

Screener crusher’s other structural components.

Maintenance item

Section of the instruction manual

Schedule

Daily inspection/cleaning

4.1.1

Daily / every 8 hrs

Weekly inspection and lubrication of bearings

4.1.2

Weekly / every 40 hrs

Extensive maintenance

4.2

Annually / every 500 hrs

Replacement of wear parts

4.3

When necessary

4.1

Maintenance work in connection with use

WARNING  
WARNING  
WARNING  
WARNING  

WARNING

 

Before inspections and maintenance work performed in connection with use, turn off the base machine and depressurise the hydraulic system by moving the control lever of the auxiliary hydraulic system with only the starter motor turned on. Under no circumstances place your hands between rotating parts while the Screen crusher is attached to the base machine.

Exposure to high-pressure oil spray or getting caught between rotating parts causes a risk of death or serious injury.

Exposure to high-pressure o il spray or getting caught between rotating parts causes a risk of
Exposure to high-pressure o il spray or getting caught between rotating parts causes a risk of

If any damage or faults are observed in the inspected machine components, these must be

rectified before work begins.

4.1.1

Daily inspection (8 hrs)

2 4 1 3
2
4
1
3

4.1.2 Weekly inspection (40 hrs)

1. Remove any stones or other objects

caught between the blades.

2. Check that the operating hoses are not damaged and that the connections do not leak [1].

3. Visually inspect the mounting of the adapter[2] on the base machine and Screener crusher.

4. Check the condition and mounting of wear parts [3].

5. Check the condition of the warning labels [4].

6. Check that there is no damage to the frame (including cracks or deformation).

7. Check that all covers are closed and that the screws are firmly in place.

In addition to those of the eight-hour inspection, the following checks are performed:

1
1

1. Use a spanner to ensure that all the adapter bolts [1] have been tightened properly.

B A
B
A
A B C A 1 B C
A
B
C
A
1
B
C

Recommended bearing lubricants:

2. Check the axial and radial clearance in

the drum bearings by pushing the

drums up and down [A] (max. total

clearance: 1 mm) and side to side [B]

(max. total clearance: 2 mm) with a

crowbar.

3. Lubricate the drum bearings at both

ends (the picture shows only the left

side). Apply lubricant to each grease

fitting until some lubricant comes out

between the dust cover seals [1] on the

side of the drums.

Operating temperature

NLGI grade

Below 0 °C

0

0–25 °C

1

Over 25 °C

2

Use lithium-complex-based lubricants for bearings. The ALLU first-installation lubricant is Rocol Sapphire 1.

4.2

Extensive maintenance

4.2 Extensive maintenance WARNING Detach the Screener crusher from the base machine and disconnect the hydraulic
4.2 Extensive maintenance WARNING Detach the Screener crusher from the base machine and disconnect the hydraulic
4.2 Extensive maintenance WARNING Detach the Screener crusher from the base machine and disconnect the hydraulic
WARNING

WARNING

Detach the Screener crusher from the base machine and disconnect the hydraulic system before changing any wear parts, to prevent unintentional start-up. Under no circumstances place your hands between rotating parts while the Screen crusher is attached to the base machine.

Falling under a moving Screener crusher or getting caught between rotating parts causes a risk of death or serious injury!

rotating parts causes a risk of death or serious injury! Assess the condition of the drums

Assess the condition of the drums and power transmission as a single entity; often, it may be

beneficial to replace the drums and the power transmission at the same time, using a ready

drum assembly complete with bearings and chain wheels (see the spare-parts list).

The removal and mounting of the drums and power transmission and the maintenance of the

bearing units are presented in sections 4.3.7–4.3.9.

B A
B
A

1. Replace/service bearings if the total

radial clearance [A] exceeds 1 mm or

the total axial clearance [B] exceeds

2 mm (see section 4.1.2).

2. Check the condition of the bearing

grease tubes and connectors. Repair

any broken tubes/hoses and joints.

Load amounts for the lubricant: 3. Replace the chains and chain wheels if they have
Load amounts for the lubricant: 3. Replace the chains and chain wheels if they have

Load amounts for the lubricant:

3. Replace the chains and chain wheels if they have stretched more than 60 mm, as shown in the picture. Always replace the chains and chain wheels at the same time.

4. Change the power transmission system lubricant. Remove the old lubricant and any dirt from the chain housings before adding the new lubricant. It is easiest to apply the new lubricant through the round maintenance plate in the chain housing while the back plate is closed. The covers should be sealed in place with a silicone adhesive. Clean the surfaces before applying silicone.

The ALLU first-installation lubricant for the power transmission is Teboil Universal CLS (NLGI grade 00 centralised system lubricant).

Model

Load amount / 1 chain housing

DN/DNS

4 kg

DS/DH/DSB/DHB

5 kg

4.3

Replacement of wear parts

4.3 Replacement of wear parts WARNING Detach the Screener crusher from the base machine and disconnect
4.3 Replacement of wear parts WARNING Detach the Screener crusher from the base machine and disconnect
4.3 Replacement of wear parts WARNING Detach the Screener crusher from the base machine and disconnect
WARNING

WARNING

Detach the Screener crusher from the base machine and disconnect the hydraulic system before changing any wear parts, to prevent unintentional start-up. Under no circumstances place your hands between rotating parts while the Screen crusher is attached to the base machine.

Falling under a moving Screener crusher or getting caught between rotating parts causes a risk of death or serious injury!

rotating parts causes a risk of death or serious injury! NOTE Replace the blades regularly to

NOTE

Replace the blades regularly to prevent the material processed from causing wear to the drums’ blade-holders. At the latest, the blades should be replaced when their surface is ~ 10 mm from the blade-holders’ top surface.

surface is ~ 10 mm from the blade-holders’ top surface. 4.3.1 Replacement of blades (DN, DS,

4.3.1 Replacement of blades (DN, DS, and DH models with XHD drums)

of blades (DN, DS, and DH models with XHD drums) Special tools required: - An extractor

Special tools required: - An extractor tool

for the blades and a cotter press delivered

with the Screener crusher. - A cotter press

compatible with an impact drill is available

as an accessory (SDS Max head).

Push the cotter pin forward with the cotter press until the blade can be removed.There
Push the cotter pin forward with the cotter press until the blade can be removed.There
Push the cotter pin forward with the cotter press until the blade can be removed.There

Push the cotter pin forward with the cotter press until the blade can be removed.There is no need to detach the cotter pin completely from the blade-holder unless it is replaced at the same time as the blade.

Remove the blade. The blade is removed by pushing it upward through a slot in the side plate.

Push a new blade into its place.

Hit the cotter pin back into its place with the cotter press. Check that the

Hit the cotter pin back into its place with

the cotter press. Check that the cotter pin is

centred on the blade-holder.

NOTE

Replace the counter blades regularly, to prevent the material processed from causing wear to the frame’s counter blade-holders. At the latest, the counter blades should be replaced when their surface is at the same level as the upper surface of the counter-blade-holders.

level as the upper surface of th e counter-blade-holders. 4.3.2 Replacement of counter blades (DN, DS,

4.3.2 Replacement of counter blades (DN, DS, and DH models with XHD and X

drums)

Number

Item

Quantity

Note

1

Hexagonal screw M16 × 70, 10.9

2

200 Nm

2

Base plate M16

4

 

3

Locking nut M16

2

 

4

Counter blade

2

 

5

Counter blade lock plate

1

 
1. Loosen the mounting bolts of the counter blade’s lock plate, and remove the lock
1. Loosen the mounting bolts of the counter blade’s lock plate, and remove the lock
1. Loosen the mounting bolts of the counter blade’s lock plate, and remove the lock

1. Loosen the mounting bolts of the counter blade’s lock plate, and remove the lock plate.

2. Slide the counter blade toward the gap left by the lock plate while pushing it off the frame by means of the slots in the counter blade.

3. Remove the counter blades.

4. Check the condition of the counter- blade-holders, repairing them as necessary.

5. Place the counter blades against the counter-blade-holder, and push into place. The counter blade
5. Place the counter blades against the counter-blade-holder, and push into place. The counter blade

5. Place the counter blades against the counter-blade-holder, and push into place. The counter blade ends have locking teeth that come to rest under the contact surfaces.

6. Place the counter blades’ lock plate into its correct place, and fix in place with bolts and nuts.

4.3.3 Replacement of fine screening blades (DNS, DSB, and DHB models)

Number

Item

Quantity

Note

1

Hexagonal screw M16 ×50, 10.9

4

200 Nm

2

Lock plate NL16

4

 

3

Hexagonal screw M16 × 60, 10.9

2

 

4

Hexagonal nut M16, low version

2

 

5

Counter blade lock plate, left-handed

1

 

6

Counter blade lock plate, right-handed

1

 

7

Counter blade

1

 

Removal and installation of the top counter blade is performed as described below for the bottom counter blade.

1. Loosen the counter blade lock plate’s mounting and adjustment bolts, and remove the lock
1. Loosen the counter blade lock plate’s mounting and adjustment bolts, and remove the lock
1. Loosen the counter blade lock plate’s mounting and adjustment bolts, and remove the lock

1. Loosen the counter blade lock plate’s mounting and adjustment bolts, and remove the lock plates.

2. Push the counter blade back to release its front edge from under the teeth. Then rotate the blade forward until it slides out of place.

3. Install a new counter blade from the front of the bucket. Drop the front edge of the counter blade in front of the teeth, and push the blade into place by tilting it. Then push the counter blade under the teeth.

4. Check that the bottom of the counter blade is behind the lock plates located
4. Check that the bottom of the counter blade is behind the lock plates located

4. Check that the bottom of the counter blade is behind the lock plates located at the back of the bucket.

5. Mount the counter blade lock plate. Leave the horizontal bolts loose initially, and tighten the lock plate against the counter blade by means of a vertical locking bolt. Use hard threadlocker for the horizontal bolts.

6. Tighten all the bolts and locking nuts.

4.3.4

Replacement of wear parts in TS models and changing of the end-product size

Number

Item

Note

 

1 Locking plate

 
 

2 Screen combss

 
 

3 Spacing element

 
 

4 Blade

 

5

Hexagonal screw M16 × 80

 

6

Lock plate NL16

 

7

Fender washer, 45 × 4 and 55 × 4

55 × 4 in the middle

8

Locking nut M16

 

With some TS-model Screener crushers, the screening size can be doubled/halved by

changing the arrangement of the blades and screens without detaching the drums. The

fragment size is determined by either the width of one blade or the total width of two blades.

The fragment size can be adjusted as follows:

1. TS16 (one blade)  TS32 (double blade)

2. TS25 (one blade)  TS50 (double blade)

The only component that is changed for a change in fragment size is the spacing element [3].

In addition, when larger fragments are desired, an additional screen comb [2] is required,

regardless of the Screener crusher model. The work steps required for doubling/halving the

fragment size (TS16 TS32 or TS25 TS50) are described below.

2 3 1
2
3
1

1. Remove the locking plates [1], screen

combs [2] and spacing elements [3]

from the Screener crusher.

4
4
3
3

2. Doubling the fragment size: Arrange

parallel blades [4] next to each other by moving them along the shaft.

Halving the fragment size: Separate all the blades from each other.

3. Place the spacing elements [3] specific to the desired fragment size in their places. Fix them in place temporarily with one or two bolts, to hold them in position while the combs are being installed.

3 2
3
2
2 2 A B
2
2
A
B

4. Doubling the fragment size: Place a bundle of two screen combs [2] between all non-parallel blade bundles in such a way that the screen comb ends rest in the slots in the spacing elements [3].

Halving the fragment size: Place an individual screen comb between each pair of blades.

Begin adding the screen combs from the middle, proceeding toward the sides. If the screen combs have become more worn on one side than the other, they can be turned upside down.

5. At the ends, the blade and screen comb bundles end with either one or two blades; this depends on the model (A or B). Accordingly, at the ends, the screen comb bundles [2] end with either bundles of three screen combs (in models with two blades at the end)

or two screen combs (in models with one blade at the end). A model-specific spacing element (see the previous picture [3]) directs the screen combs into the right slots in the correct number.

Check that the clearances are even along the entire bucket.

1
1
2
2

4.3.5 Replacement of TS blades

6. Install the locking plates [1].

Push the plate upwards, to prevent a

large gap between the plate and the

screen combs [2].

CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and
CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and
CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and

CAUTION

Minimise the risk of hydraulic oi l entering the environment by having basins and material

Minimise the risk of hydraulic oil entering the environment by having basins and material absorbing any leaks readily available while opening the covers of the chain housings!

Number

Item

Note

1

Locking plate

 

2

Screen combs

 

3

Spacing element

 

4

Drum

 

5

Drum flange

 

6

Sleeve

 

7

Dust cover

 

8

Bearing unit

 

9

Hexagonal screw M16 × 80

 

10

Lock plate NL16

 

11

Fender washer, 45 × 4 and 55 × 4

55 × 4 in the middle

12

Locking nut M16

 
2 3 1
2
3
1
4
4
8–11 5 6 7
8–11
5 6
7
2 3 1 4 8–11 5 6 7 1. Remove the locking plates [1], ccreen combs

1. Remove the locking plates [1], ccreen combs [2], and spacing elements [3] from the Screener crusher.

2. Detach the drums [4] in the manner specified in section 4.3.7.

3. Remove the chain wheels and bearing units [8–11] from the drums, following the instructions in section 4.3.8.

4. Detach parts 5–7 from the drums.

5. Slide the blades off the shaft.

4.3.5.1

Placement of new blades on the shafts

On the drum, the blades form a spiral arrangement, sending material from the sides of the

Screener crusher rotating toward the middle when the drum moves in the normal rotation

direction. The blade pattern is symmetrical in relation to the middle line of all drums. Begin

positioning the blades on the shaft from the middle, with blade no. 1.

Number of blades per drum:

 

TS16/TS32

TS25/TS50

TS35

D

-12 TS

36

28

20

D

-17 TS

54

42

30

D

-23 TS

72

54

40

NOTE

Position the blades and the drums carefully in the correct places. Positioning blades in the wrong way could cause the blades of adjacent drums to hit each other.

ould cause the blades of adjacent drums to hit each other. ALLU D SERIES - ORIGINAL

Positioning of the blades in drums TS16 and TS32:

Positioning of the blades in drums TS16 and TS32: ALLU D SERIES - ORIGINAL INSTRUCT ION

Positioning of the blades in drums TS25 and TS50:

Direction of the drum when installed.
Direction of the drum when installed.

Positioning of the blades in drum TS35:

Direction of the drum when installed.
Direction of the drum when installed.

4.3.5.2

Mounting of the TS drums

8–11 5 6 7
8–11
5 6
7
A
A
4.3.5.2 Mounting of the TS drums 8–11 5 6 7 A 1. Mount parts 5–7 (attach

1. Mount parts 5–7 (attach the end flange [5] and the sleeve [6] to the shaft with a soft threadlocker).

2. Mount parts 8–11 in accordance with the instructions in section 4.3.8.

3. Mount the drums in line with the directions in section 4.3.7. Check that the spiral pattern [A] conforms with the picture, to ensure that the drums are installed in the right way.

4. The drum blades that are in line with each other should be positioned such that they are parallel to each other before installation of the chain. The arrangement of the chain’s links forces adjacent drums into the positions shown in the picture.

2 3
2
3
1
1
2 1
2
1

5. Install the spacing elements [3].

6. Mount the screen combs [2] in accordance with the directions in section 4.2.3. Begin adding the screen combs from the middle, proceeding toward the sides. If the screen combs have become more worn on one side

than the other, they can be turned upside down.

7. Install the locking plates [1].

Push the locking plate upwards, to prevent a large gap between the plate [1] and the screen combs [2].

4.3.6

Replacement of the bearing-protection fender

CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and
CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and
CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and

CAUTION

Minimise the risk of hydraulic oi l entering the environment by having basins and material

Minimise the risk of hydraulic oil entering the environment by having basins and material absorbing any leaks readily available while opening the covers of the chain housings!

Number

Item

Note

1

Hexagonal screw M16 × 30, 10.9

200 Nm

2

Lock plate NL16

 

3

The bearing-protection fender

 
1
1
  3 The bearing-protection fende r   1 The mounting bolts [1] of the bearing- protection

The mounting bolts [1] of the bearing-

protection fender can be found in a

vertical row inside the chain housing.

In the picture, the drums have been

removed, but it is possible to replace

the bearing-protection fender without

taking the drums out.

1. Loosen the mounting bolts.

2. Remove the bearing-protection fender. Make sure that the fender does not fall down or
2. Remove the bearing-protection fender. Make sure that the fender does not fall down or
2. Remove the bearing-protection fender. Make sure that the fender does not fall down or

2. Remove the bearing-protection fender. Make sure that the fender does not fall down or over.

3. Mount the bearing-protection fender. Support it carefully, to prevent it from falling over.

4. Fix the bearing-protection fender’s mounting bolts in their places. Use hard threadlocker for the bolts.

4.3.7

Replacement of drums

CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and
CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and
CAUTION Minimise the risk of hydraulic oi l entering the environment by having basins and

CAUTION

Minimise the risk of hydraulic oi l entering the environment by having basins and material

Minimise the risk of hydraulic oil entering the environment by having basins and material absorbing any leaks readily available while opening the covers of the chain housings!

Number

Item

Note

1

Hexagonal screw M16 × 30, 10.9

200 Nm

2

Lock plate NL16

 

3

Drum installation

 
Lock plate NL16   3 Drum installation   Special tools required: - Bearing cap key de
Lock plate NL16   3 Drum installation   Special tools required: - Bearing cap key de

Special tools required:

- Bearing cap key delivered with the